JP2008518818A

JP2008518818A - Curved honeycomb structure and manufacturing method thereof

Info

Publication number: JP2008518818A
Application number: JP2007540246A
Authority: JP
Inventors: キホパク
Original assignee: ヤンヘジュン; リーボンウ
Priority date: 2004-11-03
Filing date: 2005-10-28
Publication date: 2008-06-05
Also published as: KR20060048047A; RU2007118530A; MX2007004886A; CN101052486A; KR100628850B1; EP1807229A1; WO2006049406A1; BRPI0516924A; AU2005301542A1; EP1807229A4; RU2367537C2; US20080075917A1; CA2586626A1

Abstract

In the present invention, a flat plate made of a metal or plastic material is formed with a curved plate using a curved surface press or a vacuum forming die, and a hexagonal cell column having a honeycomb structure is formed on the curved plate so as to protrude. Are assembled and bonded together to make a curved honeycomb structure more easily, without causing problems such as distortion or swelling of the hexagonal cells. The strength is almost the same as that of the flat plate, and not only can the shape of the curved plate be freely changed, but also the production rate of the product can be increased without wasting materials.

Description

The present invention relates to a curved honeycomb structure and a manufacturing method thereof. More specifically, the present invention relates to a curved honeycomb structure formed of a composite material that is lightweight and has a curved shape, and a manufacturing method thereof.

Among the most important composite materials attracting attention in the 21st century, honeycomb structures that are ultra-light materials, especially honeycomb sandwich structures, cannot be compared with other materials in terms of specific strength (strength per weight). It has very good characteristics. Therefore, it is widely used in industrial fields that require solid and light materials from aviation and space industry, shipbuilding industry, automobile industry, construction industry, electronic components and leisure sports industry.
In general, honeycomb structures have a square honeycomb core from U.S. Pat. It is formed into a block and is cut into a necessary form. However, it is easy to form a flat honeycomb structure by horizontally cutting a square honeycomb core, but it is difficult to form a honeycomb structure by cutting it into a desired curved shape.
Among methods for forming a curved honeycomb structure, there is a method in which a flat honeycomb structure is physically bent or cut or joined to form a required curved surface form. That is, when seeing “Method of forming honeycomb panels into compound curved shapes” in US Pat. Manufacture. However, in this case, since the surface plate material of the sandwich panel is torn when being pressed with a press machine, in order to solve this problem, there is a problem that after processing, a new surface plate material must be covered and reinforced. is there. Further, when the pressing process is performed by a press machine, the hexagonal cell in the pressed portion is distorted or swells, so that the strength of the structure is weakened.

For another example, see U.S. Pat.No. 5,126,183 `` Curved paneling icluding honeycomb core material having crimps in one edge ''. The honeycomb core having a curved surface shape is formed by a method in which the wrinkles are given to the other surface and the length is different from the other surface. However, even in this case, the direction in which the core can be bent is limited to one direction, and there is a problem that it is not possible to produce various types of parts.
Looking at the largest honeycomb manufacturing company in the US, Hexcel, Cellbond, or Europe's EURO-Composite, etc., when making parts using honeycomb structures, many parts have been skilled so far Depending on the manual work of engineers, parts are made by methods such as cutting, bending, cutting, and bonding, resulting in slow production speeds and high part prices. Further, when a honeycomb core is cut and machined, a large amount of material is removed as a residue, so that the product production rate is lower than the amount of material provided, which also increases the unit cost of parts.
The present invention relates to the honeycomb disclosed in Korean Utility Model Registration No. 03550066 “Honeycomb” and No. 0354808 “Honeycomb Panel” of the same applicant as the present invention, that is, a metal plate or a plastic plate. A method of forming a honeycomb structure by providing two hexagonal cell upper and lower plates formed by hexagonal column forming by vacuum forming, laminating and bonding these plates, and attaching surface materials to both surfaces. Further improved, a curved-surface honeycomb structure is formed.
U.S. Pat.No. 2,518,164 U.S. Pat.No. 2,983,640 U.S. Pat.No. 6,272,897 U.S. Pat.No. 5,126,183 Korea Utility Model Registration No. 0350066 Korea Utility Model Registration No. 0354808

Conventionally, a curved honeycomb structure is obtained by physically bending, cutting or joining a flat honeycomb structure. However, such a method causes the surface plate material to tear, and the honeycomb sandwich panel is formed. When pressing with a press machine, there is a problem that the hexagonal cells are distorted and the strength is weakened, and when bending with one side of the honeycomb core being bent, the bending direction is unidirectional However, since it is difficult to manufacture honeycomb structures having various shapes, the method of cutting, bending, cutting out, and bonding by hand is inferior in productivity and wasteful of materials. The technical challenge is to solve these conventional problems and make it easier to produce various types of curved-surface honeycomb structures by making molds suitable for the desired application. To have.

A honeycomb structure according to the present invention is made of a metal or a plastic material, and includes an upper plate and a lower plate formed into a curved surface by a mold, and a hexagonal cell columnar convex portion and a concave portion on the surface. Polygonal or cylindrical cell pillars that are formed by projecting downward and upward from the surfaces of the upper plate and the lower plate by molds and bonded and bonded so as to mesh with each other while forming a honeycomb structure, and various materials The curved upper plate surface material and the lower plate surface material are configured to be attached to opposite surfaces of the upper plate and the lower plate, in which the cell pillars are not formed.
Further, the method of manufacturing a curved honeycomb structure according to the present invention includes a step of arranging a flat plate made of metal or plastic material between molds made of a curved surface, pressing them together to form a curved plate, A curved plate is placed between the molds having convex and concave portions in the shape of polygonal or cylindrical cell pillars, and a polygonal or cylindrical cell is applied to the surface by pressing them using a press or vacuum forming machine. The step of forming so that the column protrudes, and one of the curved plates on which the cell column is formed is an upper plate, the other is a lower plate, and the cell columns are joined and bonded so as to mesh with each other. The method includes a step of forming a honeycomb block and a step of attaching a curved upper plate surface material and a lower plate surface material of various materials to the surface without the cell pillars.

In the present invention, each flat plate made of a metal or plastic material is arranged between molds in which the shape of a hexagonal cell column is formed by a convex part and a concave part, and formed into a curved plate using a press or vacuum forming, By forming the hexagonal cell pillars of the honeycomb structure on the surface of each curved plate so as to protrude and assembling and bonding them together, a curved honeycomb structure can be produced more easily, thereby forming a hexagonal cell. The problem of defects such as distortion or swelling does not occur, the strength of the structure is almost the same as that of the flat plate, and the shape of the curved plate can be freely changed and there is no waste of materials, There is an effect that can increase the production rate of the product.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.
In the accompanying drawings, FIG. 1 shows an exploded perspective view of a curved honeycomb structure according to the present invention, a curved upper plate surface material 12 from the uppermost side, and a hexagonal cell column protruding downward from the surface. FIG. 10 shows a curved type upper plate 8 having a curved surface, a curved type lower plate 10 having a hexagonal cell column protruding upward from the surface, and a curved type lower plate surface material 14. A curved honeycomb structure.
FIG. 2 is a side view showing a state in which a flat plate 2 made of a metal or plastic material to be formed on the curved plates 4 and 6 is disposed between the concave upper mold 23 and the convex lower mold 24. The flat plate 2 can be formed into the curved plates 4 and 6 by press molding or vacuum forming using the molds 23 and 24 depending on the material of the flat plate.

FIG. 3 is a curved plate 4 made of metal or plastic material using the molds 23 and 24 of FIG. 2 in which the positions 16 for forming the hexagonal cell pillars so as to protrude downward are displayed. 2 is a curved plate 6 made of metal or plastic made using the molds 23 and 24 of FIG. 2 in which the positions 18 for forming the hexagonal cell columns so as to protrude upward are displayed. is there. FIG. 5 shows a case where the curved plate 4 of FIG. 3 and the curved plate 6 of FIG. 4 are combined, and hexagonal cells indicated by symbols a and b are continuously combined, A honeycomb structure is formed, and reference numeral 20 indicates a position of a hexagonal cell that is naturally generated by combining the hexagonal cells of the signs a and b.
According to the present invention, after the curved plates 4 and 6 are formed by the molds 23 and 24 of FIG. 2, the curved plates 4 and 6 are formed with convex portions for forming hexagonal cell pillars as shown in FIG. Curved upper plate 8 having hexagonal cell pillars projecting downward from the surface as shown in FIG. 7 and hexagonal cell pillars projecting downward from the surface as shown in FIG. Are respectively formed on the curved plate lower plate 10.

FIG. 6 shows a side view of the molds 26 and 28 for illustrating an example of a method for forming the curved upper plate 8 and the curved lower plate 10 having the hexagonal cell pillars 22 described above. As shown in the left drawing of FIG. 6, the curved upper plate 8 in which the hexagonal cell pillars 22 protrude downward from the surface as shown in FIG. As shown in the right drawing of FIG. 6, the curved lower plate 10 with the hexagonal cell pillars 22 protruding upward is formed as shown in FIG. 8 using the upper convex and lower concave molds 28. And when these are combined with each other, as shown in FIG. 9, the curved honeycomb in which hexagonal cell columns 22 formed so as to protrude into the curved mold upper plate 8 and the lower plate 10 mesh with each other. The structure is completed.

In the curved honeycomb structure of FIG. 9, an adhesive is applied to the outer surface of the hexagonal cell column 22 or an adhesive molten material is inserted between the hexagonal cell columns 22. When the curved upper plate 8 and the curved lower plate 10 are joined, the hexagonal cell columns 22 of the curved upper plate 8 are sandwiched between the hexagonal cell columns 22 of the curved lower plate 10 so as to mesh with each other. Then, all hexagonal cell pillars are bonded together to form a honeycomb.
In the case where the above-described adhesive and adhesive molten material are not used, the curved upper plate 8 and the curved lower plate 10 can be bonded together by thermal bonding after first bonding.
On the other hand, as shown in FIG. 10, the curved upper plate surface material 12 and the curved lower plate surface plate 14 made of various materials are curved curved honeycomb-structured curved surfaces in which hexagonal cell columns 22 are not formed. Bonded to the opposite surfaces of the upper plate 8 and the lower plate 10. In this case, the surface materials 12 and 14 are bonded by applying an adhesive or an adhesive molten material to the opposite surfaces, or by thermal bonding. In the conventional method, since the bonding between the honeycomb core and the surface material is performed at the contact portion between the line and the surface, the contact area is small and the adhesive strength is weak. Since the honeycomb structure as shown in FIG. 9 and the surface material are bonded to each other at the contact portion between the surfaces, when the physical strength is applied from the outside by increasing the bonding strength, the honeycomb structure and the surface material are hardly damaged. .

11 to 15 show the positions of pillars having various shapes corresponding to the positions of the hexagonal cell pillars in FIG. As shown in FIGS. 11 to 15, after creating a curved mold upper plate and a lower mold having hexagonal cell pillars, a curved mold upper plate and a curved mold lower plate are formed and joined. Thus, a curved honeycomb structure can be formed. In FIG. 11 to FIG. 15, symbol “a” indicates the positions of various shaped cell pillars projecting downward from the surface of the curved upper plate, and symbol “b” projects upward from the surface of the curved lower plate. The positions of the variously shaped cell pillars are shown. FIG. 16 shows that cell columns can be formed from asymmetric polygonal columns or columns of various shapes, for example, combinations of square and octagonal columns, cylinders, octagonal columns, quadrangular columns, or the like. . In other words, the cell columns of the curved upper plate can have different shapes and sizes than the cell columns of the curved lower plate, and the cell columns of the curved upper plate or lower plate can have different shapes. Can have a size.

FIGS. 17 and 18 show that after forming an upper plate 8 having hexagonal cell columns protruding downward from the surface and a lower plate 10 having hexagonal cell columns protruding upward from the surface, the hexagonal cell columns are formed around the respective hexagonal cell columns. FIG. 19 shows an example in which holes 30 are opened. In this manner, as shown in FIG. 19, when bonding to form a honeycomb structure, the adhesive not only adheres to the bonding surface, but also each hole 30. Into the water and glued horizontally and vertically, improving the adhesion and reducing the weight. In addition, the phenomenon that the resin or adhesive accumulates can be partially eliminated by making the holes 30.

20, 22, and 24 are drawings showing that cutting lines 32 are previously formed and placed in order to improve formability when forming hexagonal cell pillars with a metal plate using a press. Here, the code | symbol 34 shows the position of the hexagonal cell pillar, and the code | symbol 36 is a curved-surface board in which a hexagonal cell pillar is shape | molded. Generally, it is not easy to stand several hexagonal cell pillars on a metal plate by pressing. Further, it is more difficult to press the hexagonal cell pillar deeply. Therefore, by making the cutting line 32, a deep drawing effect is obtained, and the hexagonal cell pillar can be formed deeper during the press working. In addition, as shown in FIG. 24, if the cutting line 32 is created in a zigzag manner more than double, when forming, the portion connected to the zigzag spreads while the edge is further wound on the side to be molded, It can be used for metals with low stretch rate. FIGS. 21 and 23 show examples of curved plates obtained by pressing the curved plates of FIGS. 20 and 22 to form hexagonal cell columns, respectively, and the deformed shapes of the cutting lines spread on the curved plates by the press, respectively. Show. The cutting line can be produced by changing the pattern and size according to the expansion / contraction ratio of the metal. In FIG. 21 and FIG. 23, reference numeral 38 denotes a hexagonal cell pillar processed by pressing, reference numeral 40 denotes a cutting line expanded by pressing, and reference numeral 36 denotes a curved plate on which the hexagonal cell pillar is formed. It is.

Moreover, when forming the curved upper plate 8 and the curved lower plate 10 from which the hexagonal cell pillars protrude, various materials that can be used as necessary can be used. FIG. 7 shows a molding method such as injection molding, SMC (Sheet Molding Compound), BMC (Bulk Molding Compound), pulp molding (Pulp Molding), RIM (Reaction Injection Molding), RTM (Resin Transfer Molding), etc. A curved plate having hexagonal cell pillars as shown in FIG. 8 can be formed and bonded to form a honeycomb structure. Another method for making a curved plate having hexagonal cell pillars is to impregnate a resin with a stretchable woven or non-woven fabric so that the hexagonal cell pillars as shown in FIGS. 7 and 8 can protrude. The structure can be formed by a method of putting and pressing.

The method for manufacturing a curved honeycomb structure of the present invention can be applied to a field in which a streamlined structure can be produced in large quantities such as the outer shape of an automobile or an airplane.

1 is an exploded perspective view of a curved honeycomb structure according to the present invention. FIG. It is a side view for showing the state by which the flat plate shape | molded by a curved-surface board is arrange | positioned between a concave upper metal mold | die and a convex lower metal mold | die. It is a perspective view of the curved-surface board shape | molded with the metal mold | die of FIG. 2 by which the site | part which shape | molds a hexagonal cell pillar so that it may protrude below is displayed. It is a perspective view of the curved-surface board shape | molded with the metal mold | die of FIG. 2 by which the site | part which shape | molds a hexagonal cell pillar so that it may protrude upwards is displayed. FIG. 5 is a perspective view of a curved plate for showing that hexagonal cells are continuously joined to form a honeycomb structure when the curved plate of FIG. 3 and the curved plate of FIG. 4 are joined. . It is a side view of the metal mold | die for shape | molding the curved-plate upper board and lower board which have a hexagonal cell pillar. It is a perspective view of the upper board which has a hexagonal cell pillar which protruded below from the surface shape | molded by the metal mold | die of FIG. FIG. 7 is a perspective view of a lower plate having hexagonal cell columns protruding upward from the surface formed by the mold of FIG. 6. FIG. 9 is a perspective view of a honeycomb block manufactured by joining the upper plate and the lower plate of FIGS. 7 and 8 so as to mesh with each other in the direction of the hexagonal cell pillar. FIG. 10 is a combined perspective view of a curved honeycomb structure in which surface materials are attached to both surfaces of an upper plate and a lower plate of the honeycomb block of FIG. 9. FIG. 6 is a plan view of a curved plate in which the positions of deformed hexagonal cell pillars are displayed in a honeycomb structure instead of the positions of the hexagonal cell pillars of FIG. 5. FIG. 6 is a plan view of a curved plate in which the positions of octagonal cell pillars deformed instead of the hexagonal cell pillars of FIG. 5 are displayed in a honeycomb structure. FIG. 6 is a plan view of a curved plate in which positions of deformed rectangular cell pillars are displayed in a honeycomb structure instead of the hexagonal cell pillars of FIG. 5. FIG. 6 is a plan view of a curved plate in which the positions of octagonal cell pillars deformed instead of the hexagonal cell pillars of FIG. 5 are displayed in a honeycomb structure. FIG. 6 is a plan view of a curved plate in which the positions of deformed circular cell pillars are displayed in a honeycomb structure instead of the hexagonal cell pillar positions of FIG. 5. FIG. 6 is a plan view of a curved plate in which positions of polygonal cell columns combined instead of the hexagonal cell columns of FIG. 5 are displayed in a honeycomb structure. It is the perspective view of the curved board which showed the example which opened the hole in the upper board and lower board which have the shape | molded hexagonal cell pillar of FIG. FIG. 9 is a perspective view of a curved plate showing an example in which holes are formed in the upper plate and the lower plate having the molded hexagonal cell pillars of FIG. 8. FIG. 19 is a perspective view of a honeycomb block having a hole formed by overlapping FIG. 17 and FIG. 18. It is a top view of the curved board for showing the state where the cutting line was drawn beforehand, before processing a hexagonal cell pillar with a press. FIG. 21 is a plan view of a curved plate for showing FIG. 20 in a state where a hexagonal cell column is completed by press working. It is a top view of the curved board for showing the state where the cutting line was drawn beforehand, before processing a hexagonal cell pillar with a press. It is a top view of the curved-surface board for showing the state which completed the hexagonal cell pillar by press work in FIG. It is a top view of the curved-surface board for showing the state which processed the cutting line by double before processing a hexagonal cell pillar with a press.

Explanation of symbols

2, 4 Curved surface plate, 6 Curved surface plate, 8 Curved surface type upper plate, 10 Curved surface type lower plate, 12 Curved surface type upper plate surface material, 14 Curved surface type lower plate surface material, 16, 18, 20, 22 Hexagonal cell column, 23 concave upper mold, 24 convex lower mold, 26 mold, 28 mold, 30 holes, 32 cutting line, 34 position of hexagonal cell pillar, 36 curved plate on which hexagonal cell pillar is formed, 38 press Hexagonal cell column processed by, cutting line expanded by 40 press

Claims

An upper plate and a lower plate made of metal or plastic material and formed into a curved surface by a mold,
The mold is provided with hexagonal cell pillar-shaped convex portions and concave portions on the surface, and is formed to project downward and upward from the surface of the upper plate and the lower plate, respectively, and bonded and bonded so as to mesh with each other while forming a honeycomb structure. A polygonal or cylindrical cell column,
It is composed of various materials, and is composed of a curved upper plate surface material and a lower plate surface material attached to opposite surfaces of the upper plate and the lower plate where the cell pillars are not formed. Curved honeycomb structure.
The curved honeycomb structure according to claim 1, wherein the polygonal cell pillar includes a hexagonal cell pillar, a triangular cell pillar, a quadrangular cell pillar, or an octagonal cell pillar.
The curved honeycomb structure according to claim 1, wherein a hole is formed around each cell column of the upper plate and the lower plate having the cell column.
The upper plate and the lower plate are formed not only from a metal or plastic material but also from other materials by injection molding, SMC, BMC, pulp molding, RIM, or RTM molding method. 2. A curved honeycomb structure according to 1.
Placing a flat plate of metal or plastic material between molds made of curved surfaces, and bonding them together to form a curved plate;
The curved plate is placed between a mold having a convex part and a concave part in the shape of a polygonal or cylindrical cell column, and a polygonal or cylindrical mold is formed on the surface by pressing them using a press or vacuum forming machine. Forming the cell pillars to protrude; and
One of the curved plates on which the cell pillars are formed is an upper plate, the other is a lower plate, and the cell pillars are joined and bonded so as to mesh with each other to form a honeycomb block;
A method for manufacturing a curved honeycomb structure, comprising: attaching a curved upper plate surface material and a lower plate surface material of various materials to a surface having no cell pillars.
6. The method for manufacturing a curved honeycomb structure according to claim 5, wherein the polygonal cell pillar includes a hexagonal cell pillar, a triangular cell pillar, a quadrangular cell pillar, or an octagonal cell pillar.
6. The curved honeycomb structure according to claim 5, wherein the curved plate is formed by previously forming a cutting line at a portion where the cell column is formed in order to improve moldability, and the cell column is molded. Body manufacturing method.
The cell column is bonded by applying an adhesive to the outer surface of the cell column, or by inserting an adhesive molten material between the cell columns and bonding the cell column, or the curved surface type in which the cell column protrudes. 6. The method for manufacturing a curved honeycomb structure according to claim 5, wherein the upper plate and the lower plate are bonded together and then bonded by thermal bonding.
6. The method of manufacturing a curved honeycomb structure according to claim 5, wherein a hole is formed around each cell column of the upper plate and the lower plate having the cell columns.
The material of the upper plate and the lower plate is molded not only from metal or plastic material but also from other materials by injection molding, SMC, BMC, pulp molding, RIM, or RTM molding method. 6. A method for producing a curved honeycomb structure according to 5.